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Fuel Packaging and Storage Project WM’05 Conference, February 27-March 3, 2005, Tucson, AZ MANAGEMENT OF LEGACY SPENT NUCLEAR FUEL WASTES AT THE CHALK RIVER LABORATORIES: OPERATING EXPERIENCE AND PROGRESS TOWARDS WASTE REMEDIATION D. S. Cox, I. B. Bainbridge, K. R. Greenfield Atomic Energy of Canada Limited (AECL) Chalk River Laboratories Chalk River, Ontario, K0J 1P0, Canada ABSTRACT AECL has been managing and storing a diversity of spent nuclear fuel, arising from operations at its Chalk River Laboratories (CRL) site over more than 50 years. A subset of about 22 tonnes of research reactor fuels, primarily metallic uranium, has been identified as a high priority for remediation, based on monitoring and inspection that has determined that these fuels and their storage containers are corroding. This paper describes the Fuel Packaging & Storage (FPS) Project, which AECL has launched to retrieve these fuels from current storage, and to emplace them in a new above-ground dry storage system, as a prerequisite step to decommissioning some of the early-design waste storage structures at CRL. The retrieved fuels will be packaged in a new storage container, and subjected to a cold vacuum drying process that will remove moisture, and thereby reduce the extent of future corrosion and degradation. The FPS Project will enable improved interim storage to be implemented for legacy fuels at CRL, until a decision is made on the ultimate disposition of legacy fuels in Canada. INTRODUCTION AND BACKGROUND AECL is an integrated nuclear technology company providing services to nuclear utilities worldwide. AECL’s Commercial Operations include reactor development, design, engineering, special equipment manufacturing, project management and construction of CANada Deuterium Uranium (CANDUTM) nuclear power plants, and provision of reactor services and technical support to operating CANDU reactors. AECL also operates Nuclear Laboratories (Chalk River Laboratories (CRL), and Whiteshell Laboratories (WL)) and performs research, produces isotopes used in nuclear medicine and other applications, stores and manages nuclear wastes, and decommissions nuclear facilities. AECL’s extensive waste management activities over several decades have included operation of waste management storage and processing facilities at CRL and WL; development of the concept and related technology for geological disposal of Canada’s nuclear fuel waste; development of the IRUS (Intrusion-Resistant Underground Structure) disposal concept for low-level nuclear waste; development of dry storage technology for interim storage of used fuel; development and assessment of waste processing technology for application in CANDU nuclear power plants and at CRL and WL. An overview of AECL’s waste management activities was presented at the 2004 Pacific Basin Nuclear Conference [1]. WM’05 Conference, February 27-March 3, 2005, Tucson, AZ AECL has recently launched two large decommissioning projects to remediate the highest priority legacy wastes at the CRL site [2]. The subject of this paper is the Fuel Packaging & Storage (FPS) Project, which will deal with the legacy fuels stored in tile holes. The Liquid Waste Transfer & Storage Project [3,4], will deal with intermediate and high-level radioactive liquid wastes. AECL is also proceeding with the phased decommissioning of the WL site [5], for which the Canadian Nuclear Safety Commission (CNSC) granted a six-year decommissioning licence in early 2003. AECL has operated research reactors at the CRL site since 1947, for the purpose of nuclear energy and scientific research and for the production of radioisotopes. During the 1950s and 1960s, a variety of spent nuclear fuel wastes were produced by irradiating metallic uranium and other prototype fuels. These legacy waste fuels were initially stored in water-filled fuel storage bays for a period of several years before being placed in storage containers and transferred to the CRL Waste Management Area “B” (WMA “B”), where they have since been stored in below-grade, vertical cylindrical steel and concrete structures called “tile holes” (Figure 1). Fig. 1. Tile hole construction. Tile Holes are constructed in arrays, on a concrete pad foundation, 4.6 m deep. Two concrete tiles are stacked vertically, and sealed at the joint. A mild steel liner with closed bottom is inserted, and the annulus backfilled with concrete. The liner tube has a gasket-sealed flange, which is closed by inserting a vented shield plug. The array structure is packed with sand WM’05 Conference, February 27-March 3, 2005, Tucson, AZ between the tile holes, and capped with a concrete pad. The fuel rods (typically 3.4 m long) are contained in fuel storage containers, typically surrounded by baskets. WMA “B” was established in 1953, and continues to be operated as a licensed waste management facility at CRL. Various designs of tile holes have been used to store high level wastes, including irradiated fuel and hot cell wastes. Tile hole storage structures are engineered to shield the radioactivity of these wastes, and contain any contamination, and thereby prevent the spread of radioactivity into the environment. In this regard, their performance is being confirmed through an ongoing physical inspection program, and a Groundwater Monitoring Program. This program concentrates on radiological and non-radiological constituents in groundwater in the vicinity of the storage facilities, and since its full inception in 1997, has confirmed that the tile holes continue to meet their design intent. Although the tile holes have not released contaminants to the environment, some of the fuel in early-design tile holes is known to be degrading due to ingress of moisture. Certain fuel types, in particular metallic uranium, are quite susceptible to degradation by moisture-induced corrosion. Monitoring and inspection of these older fuel types have shown that some of the fuel storage containers and the fuel itself are corroding. Although these fuels are stored safely, continued corrosion will increase the future costs and hazards for handling the fuel and decommissioning the CRL waste storage structures. The remainder of this paper describes the operating experience that has been developed for storage of metallic uranium fuels in early-design tile holes, and the FPS Project, which will remediate those fuels by retrieving them and emplacing them in a new above-ground storage system. The new storage system is being designed for 50 years of operation, which covers an interim storage period, pending availability of a long-term high-level waste management/disposal concept for Canada. With the creation of the Nuclear Waste Management Organization (NWMO), Canada is progressing towards selecting and implementing an approach for the long-term management of Canada’s nuclear fuel waste. The NWMO, established by the Canadian government in 2002, is mandated to make recommendations on long-term waste management concepts for Canada’s used nuclear fuel in late 2005. Legacy Fuels The term “legacy fuels” is used to describe spent nuclear fuels that were generated during the nuclear development program in Canada, primarily in the 1950s and 1960s. There are about 100 early-design tile holes containing legacy fuel in the form of long rods, 3.3 to 3.4 m in length, organized in five storage arrays in WMA “B”. The fuels were irradiated in the 1950s, 1960s, and early 1970s, and were emplaced in tile hole storage beginning in 1963. In total, this legacy fuel consists of about 700 rods (about 22 tonnes), primarily metallic uranium and uranium dioxide, clad in aluminum, and having less corrosion resistance than modern alloy- clad uranium oxide fuels. A small fraction of the legacy fuel also includes thorium metal, WM’05 Conference, February 27-March 3, 2005, Tucson, AZ uranium-zirconium, thorium-uranium mixed oxides, uranium carbide and uranium-aluminum alloy rods. Table 1 provides a summary of the legacy fuel types and quantities. Table I. Legacy Fuels to be Remediated by the Fuel Packaging & Storage Project Percent of Total Fuel Type Cladding Material (22 tonnes) Uranium Metal (flat rods) 56 Aluminum Uranium Dioxide Annular or Solid Rods 34 Aluminum Thorium Metal 5.6 Aluminum Uranium-Aluminum Alloy <1 Aluminum Uranium-Zirconium Alloy 2.5 Aluminum Thorium-Uranium Mixed Oxide 1.5 Zircaloy Uranium Carbide <1 304 Stainless Steel The rods vary in diameter from 44 to 76 mm. The burnup levels vary widely, with current decay heat of no more than about 4W per tile hole. The radiation levels also vary, up to approximately 1000 Rad/h for a fuel storage container, near contact. Up to one quarter of the legacy tile holes contain quantities of bitumen (tar), which was poured into the tile hole after the fuel storage containers were first loaded, to assist sealing of the top closure. Operating Experience AECL has been executing an ongoing monitoring, surveillance and inspection program, to ensure that the legacy fuel wastes remains in compliance with requirements, and that operational safety is maintained. The monitoring program has confirmed that water is present inside some of the tile holes. In some cases this resulted from incomplete water removal when the storage containers were originally taken out of the water-filled fuel storage bay. There has also been ingress of water into some tile holes, through degraded flange gaskets. Another source of moisture has been environmental humidity entering the tile holes through a pumping process due to atmospheric pressure changes, with cooling of moist surface air drawn into the lower temperature regions inside the tile holes, resulting in condensation and a net accumulation of moisture over time. Through any of these processes, the result is that the current fuel storage conditions are not reliably dry, and this contributes to corrosion of the fuel and the storage containers. Remedial action has been taken to remove water from the tile holes, and to limit further water ingress. A program to inspect and replace gaskets has been executed, and surface drainage around the concrete array caps has been improved. In recent years, a removable weather shield to shed precipitation has covered the arrays for the spring and winter seasons (Figure 2).
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